Prewrapped flat-folded carton



July 30, 1968 w. D. GREGG PREWRAPPED FLAT-FOLDED CARTON 4 Sheets-Sheet 2Filed Nov. 22, 1967 INVENTOR. WILLIHM D. B12555 BY ATTOPNEV July 30,1968 w. D. GREGG PREWRAPPED FLAT-FOLDED CARTON 4 Sheets-Sheet 5 FiledNOV. 22, 1967 m T N w m QQIILLIFIM D. E2555 ATTORNEY y 0, 1968 w. D.GREGG 3,394,867

PREWRAPPED FLAT-FOLDED CARTON Filed NOV- 22, 1967' 4 Sheets-Sheet 4INVENTOR. WILLIHM D. BREEZE;

ATTORNEY United States Patent 3,394,867 PREWRAPPED FLAT-FOLDED CARTONWilliam D. Gregg, 49 E. Ivy Lane, Cherry Hill, NJ. 08034 Filed Nov. 22,1967, Ser. No. 685,070 9 Claims. (Cl. 229-37) ABSTRACT OF THE DISCLOSUREA two-corner glued carton has a sheet of decorative wrapping paperapplied to it. The edges of the wrapping are protected by the foldedcarton in the flat-folded storage condition. The carton and wrapping areformed to provide a sturdy carton and a neatly folded and sealedwrapping upon erection and closure of the carton.

This invention relates to fiat-folded cartons and particularly to acarton that has a wrapping preattached to it so that the carton can beerected, filled and wrapped quickly.

Pre-wrapped cartons are especially useful in department stores and thelike. A clerk in a department store and the like must often spendsubstantial time periods engaged in such wrapping of gift packages,especially in holiday periods, U.S. Patent No. 2,479,456 describe apro-wrapped foldable carton.

It is among the objects of this invention to provide a new and improvedflat-folded carton having a preattached wrapping.

Another object is to provide a new and improved prewrapped carton inwhich the fragile edges of the wrapping are protected in the fiat-foldedstorage condition.

Another object is to provide a new and improved prewrapped flat-foldedcarton, which is readily and conveniently erected, filled withmerchandise, and closed and sealed in a neat, gift-wrapped package.

Another object is to provide a new and improved prewrapped flat-foldedcarton that is suitable for gift-wrapped packages.

In accordance with one embodiment of this invention, a generallyrectangular foldable carton blank is formed with a front panel, bottomwall, hinge panel, top wall, and top panel, which are integrally joinedby fold lines in that order. Side flaps are provided for the bottom andtop walls, and side ears for the hinge and top panel. A two-corner gluedand folded bottom section is formed by ears connecting the sides of thefront panel and the flaps of the bottom wall. A rectangular wrappingsheet is attached at its ends to the bottom wall and the top panel, andextends loosely therebetween to cover the top and bottom walls and thetop and hinge panels. The wrapping sheet has a width greater than thatof the walls, and its edges terminate within the top-wall flaps and thehinge and top-panel ears. In the storage condition of the cartons, theyare folded flat at the intermediate fold line between the hinge paneland the top wall. Thereby, the edges of the wrapping sheet are protectedby the overlapping carton sections from bruises and tearing duringhandling. Upon erection of the folded bottom section, it may be readilyfilled with merchandise and the top section folded over for closure ofthe-box with the top-wall flaps inserted within the bottom flaps and thetop panel over-lapping the front panel. The cars of the hinge and toppanels guide the folding of the wrapping at each end of the closedcarton and form two neat wrapping folds, which, in turn, form twoadditional transverse wrapping folds that are closed and sealed tocomplete the package. Overlapping sections of these ears and thebottom-wall flaps are provided with suitable adhesive that isself-adhering to seal the ends of the carton. Similarly, the wrappingfolds are also provided with adhesive to complete the sealing. Thewrapping sheet has a portion extending outwardly from the top panel,which overlaps the bottom-wall wrapping upon closure of the box. Thisoutwardly extending section carries an adhesive for sealing that edge ofthe wrapping.

The foregoing and other objects of this invention, the features thereof,as well as the invention itself, may be more fully understood from thefollowing description when read together with the accompanying drawing,in which:

FIG. 1 is a plan view of a carton blank partly in section with attachedwrapping sheet embodying this invention;

FIG. 2 is a plan view of a pre-wrapped folded carton with parts insection formed from the blank of FIG. 1 and assembled with the bottomsection assembled in two glued and folded corners;

FIG. 3 is a plan view of the assembled carton of FIG. 2, illustrated inthe flat-folded storage condition;

FIG. 4 is a perspective view of the carton of FIG. 2, illustrated in theerected condition with the lid partly closed;

FIG. 5 is a perspective fragmentary view of the top and sides of thecarton of FIG. 2 in the erected condition with the lid closed;

FIG. 6 is a perspective fragmentary view similar to that of FIG. 5 andillustrating the folding of an end of the carton;

FIG. 7 is a perspective fragmentary view of the bottom and sides of theerected and sealed carton of FIG. 2; and

FIG. 8 is a perspective view of the erected carton of FIG. 2 with partof the wrapping torn away and the top section opened.

In the drawing, corrresponding parts are referenced throughout bysimilar numerals.

In FIG. 1, there is shown a carton blank 10 made of relatively stifffoldablc material such as paperboard or the like. Overlying the blank 10is a rectangular sheet of relatively flaccid wrapping paper, such as thewrappings customarily used for gift packages and the like. The blank 10is formed from a generally rectangular sheet and is cut and scored toform a front panel 14, a bottom wall 16, a hinge panel 18, a top wall20, and a top panel 22; fold lines 15, 17, 19 and 21, respectively, areformed between these successive sections. On each side of the bottomsection 16 is a pair .of generally rectangular side flaps 24 and 25, andhinged to the latter flaps, adjacent to the front panel 14, are two ears26 and 27, respectively. A pair of side flaps 28 and 29 are hinged tothe top wall 20, a pair of side ears 30 and 31 hinged to the hinge panel18, and a pair of side ears 32 and 33 hinged to the sides of the A toppanel 22.

The blank 10 is of generally rectangular form, and the sections thereofare formed by side fold lines 40 and 41 so that the top and bottom walls16 and 20 are of generally the same dimension, as are the panels 14, 18and 22. The flaps 28 and 29 have curved ends 34 that are cut back topermit ease of insertion in the assembled carton; in other respects thelateral width of the flaps 24, 25, 28, 29 and the ears 30, 31, 32 and 33are the same. The rectangular wrapping sheet 12 has a width sufiicientlygreat to overlap the side flaps and ears, but not to extend beyond thoseparts, so that the relatively fragile edges of the sheet 12 areprotected against injury by the flaps and the ears. It has been foundthat the wrapping sheet dimensions are best chosen to terminate withinthe flaps and ears, as illustrated in FIG. 1, which arrangement protectsthe edges of the wrapping and affords a neatly wrapped package uponfolding of the paper as described hereinbelow. One end of the sheet 12is glued to the top wall 16 along the fold line 15 between that wall 16and the front panel 14. A narrow glue area 38 at the fold line 15 andthe edge of sheet 12 extends between the flap fold lines 40 and 41; theportions of the sheet 12 that overlap the flaps 24 and 25 are leftunglued. The wrapping 12 is left unglued over the remainder of thebottom wall 16, the hinge panel 18, the top wall 20, and a portion ofthe top panel 22. At the outer edge 42 of the top panel 22, the sheet 12is secured thereto by the glue area 44, which extends over the entirepanel 22 between the fold lines 40 and 41. As indicated in the cut-awaysection in the lower left corner of FIG. 1, an end section 46 of thewrapping sheet 12 is folded back around the front panel 22 and parts ofthe associated ears 32 and 33; this end section 46 is not glued to thetop panel 22.

The two outer side corners of front panel 14 are scored on therespective fold lines 48 and 49 to form triangular sections that receivean application of glue 50 on the reverse face thereof as viewed inFIG. 1. Glued corners for the bottom section of the carton are formed,as indicated in FIG. 2, by folding in the front panel 14, folding backthe glued panel corners at the lines 48 and 49, folding the cars 26 and27 back onto the side flaps 24 and 25, and folding those flaps inward sothat the ears 26 and 27 overlap the corners 48 and 49. The overlappingtriangular areas 52 of cars 26 and 27 also have glue applied thereto forfastening to the glued areas 50 on the corners 48 and 49. Thereby atwo-corner glued bottom section of the carton is formed.

For the purpose of fastening the ears 30-33 to the flaps 24 and 25 uponerection of the folded box, selfadhering adhesive, such as that of thelatex type, is applied to corresponding portions of these ears andflaps. As viewed in FIG. 2, the cars 30 and 31 receive adhesive in theareas 54 and 55, which overlap respectively with the adhesive areas 56and 57 on the bottom side flaps 24 and 25, respectively; and the areas58 and 59 of ears 30 and 32 overlap the corresponding areas 60 and 61 onthese side flaps 24 and 25. The wrapping sheet 12 carries similar areasof self-adhesive 62 and 63 on the outer face thereof and incorresponding locations of those sections 64 and 65 of the sheet thatoverlap the bottom side flaps 24 and 25. On the inside face of the sheet12, on those sections 66 and 67 that overlap the top side fiaps 28 and29, are correspondingly located areas 68 and 69 of self-adhesive. Agummed adhesive strip 70 is applied to the inside face of the overlapsection 46 of the wrapping; the strip 70 has a substantial length toprovide a good closure of the overlap section, as described below, andis provided with a cover tape to protect the gum adhesive in storage,which tape is removed for sealing the section 46 of the wrapping.

Various decorations may be attached to the outer face of the wrappingsheet 12, and a strip of ribbon 71 is shown extending loosely from thefold line 15 to the outer edge 42 of top panel 22 and attached by glueor the like to the wrapping sheet at each end. The top wall 20 isperforated along the fold lines 40 and 41 connecting it to the sideflaps 28 and 29, as indicated by the dot-dash lines 72 and 73. Anotherperforated line 74 extends transversely between perforations 72 and 73and across the central portion of top wall 20. A finger tab 76 is cutinto the central portion of top wall 20 between two portions ofperforated line 74. As explained below, tab 76 is used to open theclosed and sealed carton, that is, to tear open top wall 20 along theperforated line 74, and thereafter along lines 72 and 73, after thewrapping has been torn from the carton.

FIG. 3 illustrates the pre-wrapped carton in its fiatfolded conditionfor storage. The folded carton, as viewed in FIG. 2, is folded againalong fold line 19 between the hinge panel 18 and the top wall 20, toplace the unit in its storage condition. The fold line 19 is the medialline between the edges 15 and 42, since the hinge and top panels 18 and22 have the same width as do the bottom and top walls 16 and 20.Accordingly, in the storage condition shown in FIG. 3, the edges 15 and42 substantially coincide. Thus, in this condition, all of therelatively fragile side edges of the wrapping 12 terminate within andare protected by the flaps 28 and 29 and cars 32 and 33 of the top halfof the folded-down carton. At the bottom section of the carton, thewrapping portions 64 and 65 that are not covered by the folded-inflaps24 and 25 are similarly protected by the flaps 28 and 29 and cars32 and 33 which overlie those portions of the wrapping. In the storagecondition, the carton has a rectangular form without projections, sothat, for storage and shipment, a plurality of such folded cartons ofFIG. 3 may be stacked in a box or other suitable container, and thestiff paperboard protects the wrapping. Similarly, in use in adepartment store or the like, the folded carton of FIG. 3 is a neat unitand the wrapping is also protected during handling.

When a carton is to be used, it may be placed on a table in the positionillustrated in FIG. 3, and the top half folded back to the positionillustrated in FIG. 2 (as viewed from the right side of the drawing).The tape covering the gummed adhesive strip 70' is removed, and thebottom section opened up by erecting the front panel 14 and the cornersat each end. The merchandise is inserted in the bottom section of thebox, the side flaps 28 and 29 are folded up, and the lid of the 'box isfolded up at the hinge-panel line 17 to form a closed rear panel for thebottom section. The side flaps 28 and 29 are folded inside the sideflaps 24 and 25 to reinforce and strengthen the bottom section of thecarton. The top panel 22 is folded at the fold line 21, and the overlapsection 46 of the wrapping is folded around the edge 15 and under thebottom section, where the gummed tape 70 is sealed to the wrapping alongedge 15. The lid of the carton is thus closed and sealed, as shown inFIG. 5, whereas the ends are open, and the ears protrude.

Thereafter, as shown in FIG. 6, the ears 30 and 32 at the hinge panelare folded in together with the overlapping portions 74 and 76 of thewrapping associated with each ear. The folding in of the ears 30 and 32seals the end of the paperboard carton, since the adhesive areas 54 and56 mate and seal, as do the adhesive areas 58 and 60. As the car 32 isfolded in by the clerks finger, the overlapping wrapping section 76 iscarried with it; thereby, a fold line 78 is formed on the wrappingsection 66, and a similar fold line 80 is formed on the wrapping section64 and the overlapping wrapping portion 46. This overlapping portion 46carries the corner of the wrapping 64 with it and ensures a neat foldline 80. Similarly, ear 30 is folded in together with the wrappingsection 74 to form fold lines 82 and 84 therein. The wrapping at the endof the box is closed by folding up the remaining portion of wrappingflap 64 and folding down over it the corresponding portion of wrappingflap 66, so that the adhesive 68 seals against the adhesive 62. In asimilar fashion, the other side of the box is closed and sealed, and aneatly folded wrapping is completed, as shown in FIG. 7.

The carton underlying the wrapping is sturdy and securely closed by thesealed ears 30-33, and the outer decorative wrapping has all theappearance of the usual custom-wrapped gift package. The gift wrappingis loosely formed around the carton, except at the fastened ends, in thecustomary fashion, so that it may be torn off, which is a desirablecharacteristic of such a package. The ribbon is wrapped around thecarton in a suitable fashion, and does not require any additional,handling by the clerk. If

desired, a fancy bow may be'readily attached by an adhesive or the likein a well-known manner.

When the gift wrapping 12 is partly torn off and the top Wall 20exposed, the carton itself is readily opened by pressing down on thefinger tab 76 in the top wall 20', and breaking that wall by way of theperforation line 74 and the perforation lines 72 and 73, as shown inFIG. 8. Thereby, the contents of the carton are readily removed, andthey can be returned thereto for display in the carton which wouldordinarily be partly covered by the gift wrapping. The sealing of ears30-33 to flaps 24 and 25 by means of the adhesive areas 54-61 guides theone who opens the package to tear off the wrapping over the top wall 20of the carton to expose the perforations 72-74 and tab 76 for openingthe carton. The sealed ears also provide a sturdier carton and ensureclosed carton ends even if the flaps 64 and 66 are inadvertentlyunsealed. If desired, the adhesive areas 62, 63 and 68, 69 on thewrapping flaps 64-67 may be omitted, and the clerk may apply strips ofconventional gummed tape in the usual fashion to seal these flaps afterthey have been folded by pressing down the ears 62, 63 and 68, 69 in themanner described above.

The overlap portion 46 of the wrapping may be omitted and the adhesivestrip 70 used on the inside face of the top panel 22 to seal the latterto front panel 14. However, the illustrated embodiment is preferred inthat the seam of carton fold line and edge 42 and the edges of thewrapping are neatly covered by the wrapping overlap 46. The latteroverlap 46 interlocks with the free front edge of wrapping portion 64 asthe car 32 is pressed down (FIG. 6) to form a neat fold line 80, whichassists the clerk in completing the wrapping operation. The wrappingoperation is guided by the carton construction so that no skill orspecial effort is needed, and a complete wrapping is achieved which isneat and has all the appearance of a carefully hand-wrapped package. Theadhesive strip 70 may be omitted, and the clerk may apply a strip ofgummed tape instead. Alternatively, a punched lock tab may be formed inthe front and top panels 14 and 22 (and through the wrapping that coverspanel 22) in a well-known fashion.

As may be seen in FIG. 4, the glued corners of the bottom section areformed with cars 26 and 27 hinged to the side flaps 24 and 25 andattached along the front panel 1 4. These corners may be formed withsimilar ears hinged to the ends of front panel 14 and glued to the sideflaps 24 and 25. However, the illustrated embodiment is preferred inthat the ears 26 and 27 are out of the path of and do not interfere withflaps 28 and 29 as they are inserted inside of flaps 24 and 25.

In manufacturing this pre-wrapped, flap-folded carton, the carton blankis cut, scored and otherwise prepared, and the wrapping sheet is cut,and the gummed tap and adhesive and glue areas applied thereto. Theoverlap 46 of the wrapping is folded over the edge 42 of the carton, theglued area 44 is sealed, and the paper rolled down smoothly to the otherend 15 of the carton where the glued area 38 is sealed.

Thus, this invention provides a new and improved fiatfolded cartonhaving a pre-attached wrapping. The carton has a flat-foldedconstruction which is compact and rectangular in form for stacking in astorage or shipping container and which ensures protection of the edgesof the wrapping. The carton is quickly erected, packed, and closed andsealed in a neat gift-wrapped package. The above described embodiment ispresented by way of illustration, and not by way of limitation, andvarious modifications and variations will be apparent to those skilledin the art. For example, the invention may be used with cartons ofdifferent sizes and shapes and different proportions of panel and walldimensions. Staple or other fasteners may be used in place of the gluefor the fastened corners of the bottom section. The wrapping sheet maybe glued or otherwise fastened to said carton blank at variouslocations. The pre-wrapped carton of this invention may be used forvarious types of packages for gifts, for specially Wrapped cartonscontaining alcoholic beverages, candy, cigarettes, soaps, and forspecial packaging of seasonal retail items of all types that may requireappropriate wrapping.

What is claimed is:

1. A prewrapped carton comprising:

a sheet of foldable material cut and scored and including a front panel,a bottom wall, a hinge panel, atop wall, and a top panel integrallyjoined by fold lines in that order;

side flaps hinged to opposite sides of each of said top and bottomwalls,

side ears hinged to opposite sides of each of said hinge and top panels,

and means including additional ears forming a foldable preattachedcorner between each of said bottom wall flaps and the adjacent side ofsaid front panel;

said foldable sheet being folded flat at said hinge panel in the storagecondition with said top wall overlapping said bottom wall;

and a rectangular sheet of thin wrapping attached at spaced parts tosaid foldable sheet with unattached parts therebetween and extendingfrom said front panel to said top panel, said wrapping being of a widthgreater than said walls to overlap said panel ears and top wall sideflaps and terminating within said top wall side flaps, whereby the edgesof said wrapping are protected by said panel ears and top wall sideflaps, in said storage condition;

said top wall side flaps being foldable against said bottom wall sideflaps in the erected condition;

and said panel ears being foldable together with portions of theoverlapping wrapping sheet at the corners of said bottom side flaps tooverlap said side flaps and form wrapping corners thereat and to formfoldable flaps of said wrapping that overlap to close the sides of saidcarton;

whereby said carton is readily erected and said wrapping sides areneatly folded to form a wrapped carton.

2. A prewrapped carton as set forth in claim 1, wherein saidpre-attached corners are folded in said storage condition with saidfront panel and bottom side flaps folded inward, and said top side flapsinsertable within said bottom side flaps in said erected condition.

3. A prewrapped carton as set forth in claim 2, wherein said additionalears are respectively hinged to said bottom wall flaps and attached tothe sides of saidfront panel.

4. A prewrapped carton as set forth in claim 2, wherein said hinge andtop panel ears and said bottom wall flaps carry areas of adhesive incorresponding locations that overlap upon erection and closure of saidcarton, whereby said hinge and top panel ears are attached to saidbottom wall flaps.

5. A prewrapped carton as set forth in claim 4, wherein portions of saidwrapping overlapping said top and bottom wall flaps carry areas ofadhesive in corresponding locations that overlap upon erection andclosure of said carton, whereby said wrapping flaps are attached to eachother to close the sides of said carton.

6. A prewrapped carton as set forth in claim 2, wherein said wrappinghas a portion extending outwardly beyond the outer edge of said toppanel and, upon erection and closure of said carton, overlapping saidbottom wall and a portion of said wrapping extending sidewardly fromsaid bottom wall, whereby said sidewardly extending wrapping portion isengaged by said outwardly extending portion and folded in the formationof said foldable wrapping flaps.

7. A prewrapped carton as set forth in claim 6, wherein said outwardlyextending wrapping portion carries an 7, area of adhesive for attachmentto the bottom wall wrapping portion upon erection and closure of saidcarton.

8. A prewrapped carton as set forth in claim 6, wherein said outwardlyextending wrapping portion is folded under said top panel and protectedthereby in said storage condition. a

9. A prewrapped carton as set forth in claim 5, wherein one of saidwalls has a perforated section for opening said one wall of the erectedand closed carton upon removal of said wrapping therefrom.

References Cited UNITED STATES PATENTS 2,479,456 8/1949 Arthur 229-142,828,060 3/1958 Brown 229-,-37 3,257,068 6/1966 Wright 229-44 3,343,7509/1967 Desmond et al. 22987 DAVIS T. MOORHEAD, Primary Examiner.

